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aijstpme 2013 6 1 11 17 design and development of electronic fuel injection control system program for single cylinder diesel engine sittichompoos combustion technology and alternative energy centre ctae college ...

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                                                                                                                                       AIJSTPME (2013) 6(1): 11-17 
                                     
                                     
                                    Design and Development of Electronic Fuel Injection Control System Program for 
                                    Single Cylinder Diesel Engine 
                                     
                                                                            
                                    SittichompooS.
                                    Combustion Technology and Alternative Energy Centre-CTAE, College of Industrial Technology, KMUTNB, 
                                    Bangkok, Thailand 
                                     
                                    Theinnoi K. 
                                    Combustion Technology and Alternative Energy Centre-CTAE, College of Industrial Technology, KMUTNB, 
                                    Bangkok, Thailand 
                                     
                                    Sawatmongkhon B. 
                                    Combustion Technology and Alternative Energy Centre-CTAE, College of Industrial Technology, KMUTNB, 
                                    Bangkok, Thailand 
                                     
                                    Abstract 
                                    This research aimed to evaluate mainly on engine-out emission of a single cylinder diesel engine on two 
                                    conditions  of  fuel  injection  system:  mechanically  and  electronically  controlled  fuel  injection  system.  The 
                                    research engine was modified to have changeable fuel injection system. The in-house built PECU was capable 
                                    of producing 3 consecutive injection pulses. Fuel pressure was adjusted between 500 bar to 1100 bar. Engine 
                                    with electronically controlled fuel injection system produced less NOx than original engine approximately 
                                    50%. However, as the result of higher injection pressure HC and CO were increased due to fuel impingement 
                                    on combustion chamber.  
                                     
                                    Keywords: Electronically controlled fuel injection system, Common Rail fuel injection system, Single cylinder 
                                    diesel engine, Multiple injection 
                                     
                                    1  Introduction 
                                    Diesel  engines  usage  has  been  highly  demand                                                                                             strategies have been developed to improve the engine 
                                    compared  to  spark  ignition  engines  in  order  to                                                                                         performance.  Common  Rail  (CR)  fuel  injection 
                                    simplicity,  cost  and  performance  [1].  Conventional                                                                                       system  is  one  of  electronically  controlled  fuel 
                                    diesel  engines  generally  employ  the  conventional                                                                                         injection system that has become the main feature for 
                                    mechanically fuel controlled injection systems. The                                                                                           CI engine nowadays. The system is able to provide 
                                    engine’s air to fuel ratio (A/F ratio) and fuel injection                                                                                     various and flexible control of injections [3,4] such 
                                    timing  are  not  precisely  controlled  under  operating                                                                                     as  injection  event,  injection  pressure,  injection  rate 
                                    conditions,  therefore;  desired  engine  performance,                                                                                        and injection number in a cycle of operation.  
                                    break  specific  fuel  consumption  (BSFC),  and                                                                                              Electronically  controlled  fuel  injection  system  has 
                                    emissions  level  (e.g.  nitrogen  oxide,  particulate                                                                                        proven to be the major improvement of diesel engine 
                                    matter) can hardly be achieved [2].                                                                                                           that  is  able  to  achieve reduction in both aspects of 
                                    In  additions,  the  growing  concern  regarding  to  the                                                                                     fuel  consumption rate and engine-out emission [5]. 
                                    global  warming  and  the  depletion  of  fossil  fuel                                                                                        Operating noise from the engine is also reduced, due 
                                    resource, the demand of diesel engine has gradually                                                                                           to  the  use  of  high  pressurised  fuel  atomiser  and 
                                    increased  due  to  the  better  fuel  economy,  higher                                                                                       sophisticated control of injections pattern. The trend 
                                    durability  and  wider  range  of  renewable  fuel                                                                                            of diesel technology has been focused on increasing 
                                    (e.g.  biodiesel).  The  researches  on  fuel  injection                                                                                      injection  pressure  and  injection  strategies,  which 
                                     
                                                                                                                                                                          11 
         
                                       Sittichompoo S. et al. / AIJSTPME (2013) 6(1): 11-17 
        achieved the higher combustion efficiency and lower           2  Experimental procedure and apparatus 
        emissions [5,6].                                              2.1  Apparatus 
        CR  system  has  been  employed  for  multi  cylinder         This  experimental  research  was  carried  out  on  a 
        diesel engine for passenger cars and trucks. Although         YANMAR TF DI 90,  four  stroke  single  cylinder 
        there  is  no  single  cylinder  diesel  engine  with         naturally aspiration diesel engine which is modified 
        electronically   controlled    fuel   injection   system      and equipped with conventional Common Rail fuel 
        commercialised in the market. The major advantages            injection system (Figure 1, 2 and 3). The CR control 
        of  CR  system  can  be  referred  in  terms  of              injection  period  and  fuel  pressure  are  controlled 
        improvement  in  the  thermal  efficiency  and  fuel          using  in  house  microcontroller  based  software. 
        economy compared to mechanism injection system                Combustion chamber geometry was kept unchanged. 
        diesel.  Also,  the  lower  fuel  economy  and  the           The engine specifications are given in table 1. A PC 
        controlled  emission  in  order  to  keep  within  the        programmable electronic control unit  was designed 
        current  limits  and  meet  forthcoming  scheduled            to split fuel injection into multiple injections (i.e. pre-
        stringent  emission  standards  (e.g.  Euro  6,  Tier  4,     injection,  main-injection,  and  post-  injection)  with 
        Low Emission Vehicle III (LEV III)). Therefore, the           adjustable fuel pressure up to 2000 bar. 
        introduction  CR  system  in  single  cylinder  diesel         
        engine  should  be  an  interesting  method.  However,        Table 1: Experiment engine details. 
        the high cost implement is the main disadvantage in 
        this small system.                                                   Engine              Before            After 
        There are several factors contributed in order to have            specification       Modification  Modification 
        a  fully  controlled  in  fuel  injection  such  as  fuel             Model                YANMAR TF-DI 90 
        injection pressure, injection timing, dwell time, and 
        amount of fuel injected [7]. Fuel injection pressure is            Number of                         1 
        the  main  advantage  of  CR  system  as  it  can  be               cylinders 
        controlled independently from engine speed [8] that               Cylinder-head          2 valve, Over Head Valve 
        results in designable injection pressure at any engine 
        conditions.    Sophisticated    control    of   injection      Combustion system            Direct Injection-DI 
        pressure  in  the  rail  is  needed  to  optimise  with  the       Bore/stroke                85 mm/87 mm 
        variation  of  pressure  drop  between  each  injection 
        event [9] which affects actual fuel amount injected.              Displacement                           3 
        Dwell time is a crucial parameter that has the very                  volume                       493 cm
        impact on combustion process [5]. Previous studies             Compression ratio                  16.6:1 
        showed  the  various  length  of  dwell  time  utilised 
        between 0.5 – 1.8 ms [5, 7, 8, 10, 11]. The reduction             Cont. Rating                5.9@ 2400rpm 
        of  dwell  time  is  mainly  development  with  fuel              Output (kW) 
        injector  by  having  faster  method  of  actuation.  The      Max. Output (kW)               6.6@ 2400rpm 
        approaches  to  0  µs  of  dwell  time  capable  of                                    Bosch Type      Electronically 
        producing close couple multiple injection or injection                                Mechanically     controlled fuel 
        trains [3] which enable more advance combustion.                 Injection system     Fuel injection      injection 
        In this study, a preliminary work was to design and                                       system           system 
        install electronically controlled fuel injection system                                   Engine 
        into  single  cylinder  agriculture  diesel  engine.  The          Fuel pump           mechanically      Electrically 
        experiment on engine performances and engine-out                    mounting              driven           driven 
        emission  were  carried  out  for  both  conditions  of 
        engine before and after modification.                          
                                                                      Horiba     MEXA-584L  gas  analysis             included 
                                                                      measurement of CO , CO by non-dispersive infrared 
                                                                                            2
                                                                      (NDIR), O2 by magnetopneumatic method, NOX by 
                                                                      chemiluminescence  detection  (CLD)  and  total 
                                                                      unburned hydrocarbons by flame ionisation detector 
                                                                      (FID).  H2  concentrations  were  measured  by  gas 
         
                                                                  12 
                                                                    
                                                       
                                          SittichompooS. et al. / AIJSTPME (2013) 6(1): 11-17 
              chromatography. For all the conditions, engine out,    injection  system  were  performed  at  3  different 
              measurements of NOX, CO and HC were recorded.          injection patterns are describe in table 2. To note that 
                                                                     mode  0  represented  standard  injection  with 
                   Electric motor               High pressure        conventional  mechanically  controlled  fuel  injection 
                                                  fuel pump          system and mode 1 through mode 9 represented CR 
                                                                     electronic fuel injection system. 
                                                                     The combustion of conventional diesel fuel injection 
                                                                                                                  o
                   Crank                                             system  with  standard  injection  timing  at  20 bTDC 
                   position       P.E.C.U.         Pressure          and with CR injection system setup were examined 
                   sensor                         accumulator        under a constant engine speed of 1500 rpm with an 
                                                                     engine load of 75% of maximum engine load. 
                                                                      
                                      Rail                           Table 2: Engine Test Injection Strategies 
                    Personal        pressure            Fuel              Mode     Inj. Pressure      Inj. Pattern 
                   Computer          sensor           Injector                         (Bar)      Pilot  Main  Post 
                                                                            0          200                         
                Figure 1: CR system diagram for modified engine             1          500                         
                                                                            2          500                        
                                                                            3          500                       
                                                                            4          800                         
                                                                            5          800                        
                                                                            6          800                       
                                                                            7          1100                        
                                                                            8          1100                       
                                                                            9          1100                      
                    Figure 2: Fuel Injection Equipment Unit           
                                                                     In the case of engine after modification which fuel 
                                                                     pump was driven by external electric motor, external 
                                                                     energy as pumping work must be taken in account 
                                                                     using  equation  (1).  Wpump  was  obtained  during 
                                                                     experiment as the product of positive area of voltage 
                                                                     and current from electric motor. 
                                                                                   W1000              100%         (1) 
                                                                       t   BSFCWHHV                 
                                                                           
                                                                                                W
                                                                           
                                                                                        6           pump
                                                                          
                                                                                 3.610
                                                                           
                                                                          
                                                                     Where 
                                                                            = Thermal efficiency 
                                                                       t
               Figure 3: CR injector mounted on modified cylinder    W       = Brake work from engine (kW) 
                                      head                           BSFC = Brake Specific Fuel Consumption (g/kW.h) 
                                                                      HHV = High Heating Value of fuel (MJ/kg) 
              2.2  Procedure 
              The experimental were carried out on a engine test     Wpump = Work required by fuel pump (W) 
              rig equipped with external cooling system and an in-    
              house  built  fuel  consumption  meter.  Tests  with    
               
                                                                  13 
              
                                                               Sittichompoo S. et al. / AIJSTPME (2013) 6(1): 11-17 
             3  Results and discussion                                                                               )e  70
                                                                                                                     ko                     500 bar           800 bar           1100 bar
             3.1  Fuel injector test                                                                                 /trs60
                                                                                                                     g   50
             The experiment on fuel injector at various injection                                                    n (m
             patterns as shown in table 3 and injection pressure                                                     tio 40
             intended  to  observe  the  in-house  built  control  unit                                              tra
             capability to manipulate both fuel injection pressure                                                   ne  30
                                                                                                                     cn
             in the pressure accumulator (rail) and injection event.                                                  co 20
             Fuel  amount  injected  was  under  validation  with                                                    on  10
             standard injector test bench Bosch model: H-S/EFEP                                                      tic
                                                                                                                     jen   0
             130. Fuel injection waveform and rail pressure were                                                     I
             recorded for further investigations.                                                                                                                                                     
                                                                                                                                                       Injection Strategy                                     
             Table 3: CR Injector Test Conditions                                                                              Figure 4: CR Injector characteristics 
                                         Inj. Duration (ms)                                                      
                     Strategy           Pilot        Main  Post                                                 Injection waveforms in figure 5 show the pattern of 
                                                                                                                instantaneous  fuel  pressure  drop  of  all  injection 
                           1               0           0.1           0                                          strategies  at  injection  pressure  of  800  bar.  During 
                           2               0           0.5           0                                          double  injections  and  triple  injections,  pattern  of 
                           3               0            1            0                                          pressure drop were uniform. They occurred at the end 
                                                                                                                of injection almost the same time at falling edge of 
                           4            0.27           0.1           0                                          injection  waveform.  These  instantaneous  pressure 
                           5            0.27           0.5           0                                          drop [9] were caused by the effect of fuel in pressure 
                           6            0.27            1            0                                          accumulator (rail) begin to compensate the absence 
                                                                                                                of pressure during the control piston moving down to 
                           7            0.27           0.1          0.1                                         close  injector  needle.  This  simultaneously  happens 
                           8            0.27           0.5          0.2                                         when pressure balanced valve [3] is closing. The rail 
                           9            0.27            1           0.3                                         pressure  is  rising  again  as  the  result  of  pressure 
                                                                                                                balanced value fully closed as prove of the actual end 
             Fuel  injection  rate  from  fuel  injector  has  non-                                             of injection. The result demonstrates the potential to 
             linearity characteristic in the beginning of injection                                             reduce dwell time between pilot- main injections and 
             event as shown in figure 4. It should be noted that the                                            main-post injection down to tens of microsecond (µs) 
             amount  of  fuel  injected  under  lowest  excitation                                              which  leads  to  the  potential  for  sophisticated 
             duration  (100µs)  has  no  significant  effect  for  all                                          injection strategies. 
             injection  pressure  conditions.  As  solenoid  actuator                                                  20                                                                         1200
             requires  certain  amount  of  time  to  gain  sufficient                                              t)           Single injection      Double injection       Triple injection
                                                                                                                    lo                                                                            1000     )
             electromagnetic  force  to  lift  the  pressure  balanced                                               (V15                                                                                  r
             valve  in  the  injector  [3].  However,  the  longer                                                  mr                                                                            800      (Ba
                                                                                                                    fo                                                                                     er
             injection  duration  (500  µs)  shown  the  linearity                                                  ev 10                                                                         600      ssu
                                                                                                                    a                                                                                      re
             characteristic  compared  to  the  100  µs  injection                                                  n W         Pilot injection   Main injection   Post Injection                 400      l P
             duration to actually start the injection. The dwell time                                               tio 5                                                                                  ue
             of  1.8  ms  was  used  for  investigated  fuel  injection                                             cje                                                                           200      F
                                                                                                                    nI
             strategies  during  experiments.  The  higher  injection                                                   0                                                                         0
             pressure  and  longer  injecting  duration  resulted  in                                                      0          0.002         0.004        0.006        0.008          0.01
             increasing fuel amount injected. It can be clear that                                                                                         Time(s)                                            
             the  linear  change  of  fuel  injection  amount  for                                                Figure 5: Injection waveforms against rail pressure 
             strategy 2 and 3 (Figure 4).                                                                                            at various injection strategies. 
                                                                                                                 
                                                                                                                It  can  be  noticed  that  the  rail  pressure  utilised  in 
                                                                                                                double consecutive injection mode was higher than 
                                                                                                                other testing mode due to the overshooting with high 
              
                                                                                                           14 
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...Aijstpme design and development of electronic fuel injection control system program for single cylinder diesel engine sittichompoos combustion technology alternative energy centre ctae college industrial kmutnb bangkok thailand theinnoi k sawatmongkhon b abstract this research aimed to evaluate mainly on out emission a two conditions mechanically electronically controlled the was modified have changeable in house built pecu capable producing consecutive pulses pressure adjusted between bar with produced less nox than original approximately however as result higher hc co were increased due impingement chamber keywords common rail multiple introduction engines usage has been highly demand strategies developed improve compared spark ignition order performance cr simplicity cost conventional is one generally employ that become main feature systems ci nowadays able provide s air ratio f various flexible injections such timing are not precisely under operating event rate therefore desired nu...

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